Cellulose insulation with pest control protection

ABSTRACT

A pest control insulation building material from recycled waste paper including one or more chemical additives. The base material is fiberized, and the chemical additives may include: pesticides, disease immune additives (medicines), ammonia dust inhibitors, fire retardants, stabilizers or other additives, depending on the characteristics desired of the final product. At least one of the additives is applied as a liquid.

RELATED US APPLICATION DATA

[0001] This application claims priority from U.S. patent applicationSer. No. 08/856,717 filed May 15, 1997, now U.S. Pat. No. 6,276,619,incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates generally to a method and systemfor recycling paper products and other recyclable cellulosic materials,and more specifically to a method and system for producing stabilizedpest control insulation from waste paper products such as old newsprint,by shredding and fiberizing the waste paper stock and then treating thefiberized paper with additives which may include: pesticides such asboric acid, dust inhibitors, fire retardants and other materials,depending upon the specific application and desired characteristics ofthe final EPA Registerable Pest Control product.

[0004] 2. Description of Related Art

[0005] Discarded paper products make up approximately thirty-eightpercent of the total waste stream. With available landfill spacedecreasing, recycling of paper products has become necessary. It hasbeen found that a variety of useful products may be manufactured fromrecycled paper products. This has the dual benefit of reducing thevolume of waste, which must be landfilled, and enabling the productionof a variety of useful materials at a relatively low raw material cost.

[0006] Paper waste, such as old newsprint, can be recycled by knownrecycling techniques to produce a variety of products, includingbuilding insulation, animal bedding, soil amendment mulch, spillabsorbents, boiler fuel pellets and packaging materials.

[0007] Low-density cellulose insulation can be made from paper fibersobtained from most types of bulk waste paper stock. The most common typeof bulk waste paper stock used for insulation is old newsprint. To makecellulose insulation from newsprint, the newsprint is shredded, and thenfiberized after being mixed with, for example, a fire retardantchemical. Air cells within the shredded paper make the productlightweight and provide the thermal resistance necessary to make a highquality building insulation. Other chemical additives may be introducedto the insulation product, such as pesticides, moisture and dustinhibitors, stabilizers, fragrances and colorants.

[0008] Waste paper stock can also be recycled to produce soil amendmentmulch for soil conditioning, erosion control or seedling protection. Thepaper is shredded or chipped, and additives are introduced to fertilizethe soil, resist or accelerate decomposition, provide products ofdifferent colors and provide pesticides.

[0009] Waste paper can also be recycled to produce a spill absorbentmaterial for cleaning up liquid spills. Additives can be provided tospill absorbents which improve the absorbency of the product, resistflammability and neutralize a variety of chemicals. Boiler fuel pelletsand packing materials can also be produced from recycled paper waste.

[0010] Because of the different characteristics required for eachapplication, the methods of producing each of these products varygreatly, as do the products themselves. For example, a variety ofadditives can be provided along with the recycled paper base material toimpart characteristics desirable for the specific application.

[0011] In the field of cellulose insulation, for example, it has beenfound desirable to introduce additives including pesticides, dustinhibitors, fire retardants and stabilizers. At proper dosage levels,pesticides such as boric acid help control and kill many self-groominginsects such as termites, cockroaches, ants, silverfish, earwigs,crickets, Darkling Beetles and booklice. Cellulose insulation with theadded benefit of such pest control can prevent infestation of certaininsects. Insulation with pest control is a long-lasting alternative thatadds value to the structure, and comfort to those that dwell in thestructure.

[0012] Conventional insulation typically incorporates heavy chemicalloading (a minimum of 25 percent) in order to provide limited pestcontrol properties. Yet, the result of such heavy loading is less fiberto insulate, and more dust with which the applicator must deal.

[0013] Thus, a need exists for a method and system of providinginsulation from recycled paper that provides permanent pest controlbenefits without the loss of R-value or coverage. It would be beneficialto reduce the chemical loading of conventional insulation byapproximately 50%. It would further be beneficial to add a liquid to theinsulation that would greatly reduce nuisance dust. Further, it would bebeneficial to add a stabilizer so that the insulation will not undulysettle.

[0014] It is desirable that a “ready-to-use” insulation be provided thathas the advantages of other cellulose insulation with pest controlprotection, but without the known deficiencies in coverage and anabundance of dust that currently plague conventional celluloseinsulation.

[0015] Simply adding borates to insulation is known, but disadvantageousfor a number of reasons. For example, U.S. Pat. No. 4,454,992 toDraganov discloses a wet process apparatus for rendering cellulosicinsulation particles fire retardant by impregnating the insulationmaterial with an aqueous solution of a non-hygroscopic fire retardantcomposition and then maintaining the insulation material in a hot andhumid atmosphere for a prolonged period of time prior to drying. TheDraganov apparatus comprises: (1) a grinding mill to grind cellulosicinsulation; (2) spray nozzles to spray the insulation with water; (3)hot vapor in a humidifying conduit to humidify the wetted insulation;(4) a conditioning bin in which the insulation remains from at least 10minutes to more than an hour at temperatures from 140 to 190 degrees F.;and (5) a dryer to dry the conditioned insulation. Further, Draganovteaches the application of boric acid to waste paper immediately aftergrinding. “It is applied to the waste paper either dry during thegrinding operation or immediately thereafter in aqueous solution . . . ”Col. 3, lines 5-6.

[0016] It would be beneficial to provide the liquid additive eitherduring fiberizing, or after such fiberizing. Yet, this is contrary fromthe teaching of Draganov that boric acid in liquid form be addedimmediately after grinding. Adding borates to insulation with a liquidadditive to aid the borates absorb into the paper, to inhibit dust, andto stabilize the insulation, is believed novel.

[0017] Present cellulose insulation products are known to containborates, but not of sufficient quantities to provide effective insectcontrol. The only cellulose product that does have sufficient borates toqualify as an EPA Registered Product (InCide), lacks the process ofliquid additives that impart stability, increase coverage, and reducedust—important considerations for building owners and insulationcontractors.

[0018] Other types of cellulose products provide animal bedding. Animalbedding with pesticides and disease immune additives protects the healthof the animals using the bedding. Ammonia inhibitors can be added to theanimal bedding to help control fumes and odors caused by animal waste,thereby reducing the ventilation necessary. This reduces the expense ofelectricity used to run the ventilating fans in the animal pens, andalso reduces heating expenses, as less heat is lost through theventilation exhaust. It has been found desirable to provide a beddingmaterial having higher thermal insulative properties than known beddingmaterials, thereby also helping to reduce heating expenses.

[0019] Known bedding materials and known methods of producing thesematerials have been found to be less than adequate in use. For example,commonly used bedding materials such as wood shavings and sawdust do notprovide good thermal insulation, and are flammable. Also, thesematerials are increasingly used for other applications, such asproducing “particle board” building materials, fuels, and for otheruses. This has resulted in increased costs and decreased availability.

[0020] These known bedding materials also lack the pesticidal,disease-inhibiting and ammonia-inhibiting characteristics which havebeen found desirable, and may, in fact, promote the proliferation ofpests and disease. In the past, in order to provide known beddingmaterials such as wood shavings and sawdust with pesticidal and diseaseinhibiting qualities, it has been necessary to first lay down thebedding material, next spray the bedding with a medicinal diseaseinhibitor, and finally, spread a pesticide over the bedding. This threestep process is labor-intensive and results in substantial down-time forthe facility.

[0021] Previous attempts to use recycled paper waste as a pest controlinsulation, and as an animal bedding, and have proved less thansuccessful. Simple shredded paper with borate additives have has beenfound to be less than entirely satisfactory as an construction gradeinsulation product as it is dusty, has poor coverage and lacks astabilizer to bind the insulation in place. This is primarily due to thelack of a liquid additive to help the borates adhere to the paper and astabilizer (starch adhesive) for stability and dust-reduction. It hasalso been found that chemical additives do not adhere to the surfaces ofdry shredded paper as well as would be desired. and that the materialdoes not decompose as readily as would be desired. Further, shreddedpaper tends to compress, or lie flat when used. Because normal shreddedpaper does not “loft,” it does not provide good surface coverage (i.e.,low surface area covered per unit weight).

[0022] Thus, it has been found that a need exists a cellulose insulationwith pest control protection, and a method for making same, whichenables the addition of various additives to the recycled paper product,thereby permitting the product's characteristics to meet a variety ofrequirements.

[0023] For example, it has been found that a need exists for a methodand system for producing pest control insulation with additives toprovide fire resistance, insect control to help control insects androdents, dust control to reduce dust during application and a stabilizerto reduce settling. It is also desirable that a “ready-to-use”insulative material be provided, thereby eliminating labor-intensiveinsulation treatment procedures and their inherent facility down time.

[0024] There also exists a need for a method and system capable ofapplying a sufficient quantity of additives to a paper base material ina manner which causes the additives to adhere to the base material.

[0025] A need further exists for a method and system of producing a pestcontrol insulation material having good thermal insulating qualities,high absorbency excellent acoustical properties, high surface coverageper unit weight, and high loft (stabilization) in use.

[0026] A need also exists for an economical method and system for makinga pest control insulation and an animal bedding material meeting theseneeds from readily available waste products, thereby reducing the amountof waste to be landfilled.

[0027] It is to the provision of a method and system meeting these andother needs that the present invention is directed.

SUMMARY OF THE INVENTION

[0028] Briefly described, in a preferred form, the present inventioncomprises a cellulose insulation with pest control protection(stabilized pest control insulation) and a method and system forproducing such insulation from cellulosic waste products, such as paper,paper sludge, peanut hulls, wood shavings (green or dry), rice hulls andstraw at a greatly reduced dry chemical loading rate to knownapplications. The preferred base material is recycled paper waste, suchas old newsprint. A stabilized pest control insulation will beunderstood to be an insulation wherein one or more additives is appliedto the stabilized pest control insulation's base material in a specifiedquantity and manner, so as to impart the insulation material withcertain desired characteristics. The stabilized pest control insulationcan be used for structures to provide insulative qualities to thestructure, or in other applications such as animal bedding.

[0029] The preferred form of the system and method of the presentapplication uses mechanical and pneumatic material handling equipment tomove waste paper stock from one process machine to the next. The processmachines comprise a primary grinder, a fiberizer and a moiler. Variousother components can be included to produce a more effective andmarketable product.

[0030] The process of producing the stabilized cellulose insulation withpest control protection begins with dumping waste paper stock onto acharge conveyor. A metal detector is provided along the path of theconveyor to help prevent metal from entering the system. The waste papertravels along the conveyor and drops into a primary grinder. The primarygrinder reduces the size of the waste paper stock to paper chips. Aprimary transfer blower pulls the paper chips away from the grinder andinto a cyclone separator. The cyclone separates the paper chips from theair stream and directs them into a fiberizer tank.

[0031] Typically, the air stream from which the paper chips have beenremoved continues on from the cyclone to a dust collector. Screw feedersin the fiberizer surge tank, and a second separate air stream, meter anddirect the paper chips out of the surge tank into a fiberizer.

[0032] The fiberizer is a size-reduction process machine which receivesthe paper chips from the surge tank and grinds the relatively largechips into very small paper fibers. Because the paper is reduced to a“fiberized” state, rather than simply shredded, more surface area isexposed, and the material is fluffier than ordinary shredded paper. Thisgives the material greater loft and surface coverage, better absorbency,and better thermal insulative qualities than ordinary shredded paper.

[0033] A dry chemical additive may be provided to the fiberized materialthrough a chemical mixer/hopper connected to the fiberizer. The chemicalmixer can include a chemical feeder, which meters and feeds the additiveto a pulverizer. The pulverizer grinds solid chemical additives andblows the additives into the inlet of the fiberizer. Because thematerial is fiberized, rather than simply shredded, more surface area isexposed on which the additive may attach. Thus, increasedadditive-to-base material ratios can be achieved.

[0034] A secondary transfer blower helps to pull the paper chips fromthe fiberizer surge tank and the chemical additive from the pulverizerthrough the fiberizer, and through a moiler located downstream from thefiberizer. The moiler is an in-line process device that introduces anatomized mist of liquid additives into the paper fibers. These liquidadditives can include pesticides, disease immune additives (medicines),ammonia and dust inhibitors, fire retardants, stabilizers, and otheradditives, depending on the desired characteristics of the final pestcontrol product. It has been found that the introduction of liquidadditives through the moiler promotes greater adherence of dry additivesto the base material, thereby enabling higher additive-to-base materialratios and more accurate control of the mixture.

[0035] After the introduction of liquid additives in the moiler, theproduct is ready for packaging. A diverter valve can be installed at themoiler outlet to allow the product to be discharged to either a bulkdischarge system or a baler.

[0036] The present invention preferably incorporate two steps to producecellulosic fibers. The present process includes that cellulosic wasteproduct if first ground to form cellulosic chips, and then thecellulosic chips are fiberized to form cellulosic fibers, wherein thesetwo steps are independent from one another. Several benefits are gainedby such a two-step process as disclosed in the present application. Forexample, a surge protector can be placed between these two steps.Second, a dust removal step may be introduced between these two steps.

[0037] The present invention further preferably utilizes a non-slurryapplication of the liquid additive (in atomized form and/or through amoiler), as the preparation of a slurry bath necessitates the additionof a drying unit.

[0038] Accordingly, it is an object of the present invention to providea stabilized pest control insulation building material and a method forproducing it from a recycled cellulosic material such as waste paper,and permitting the addition of a variety of specialized additives, ineither liquid or solid form, to achieve an EPA Registered final pestcontrol product.

DESCRIPTION OF THE DRAWING FIGURES

[0039]FIG. 1 is a perspective view of a recycling system according to apreferred form of the present invention.

[0040]FIG. 2 shows, in greater detail, a preferred from of the moilerportion of the recycling system of FIG. 1.

[0041]FIG. 3 shows the bulk airlock feeder portion of the bulk dischargesystem of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0042] Referring now in detail to FIG. 1, a system 10 for recyclingcellulosic materials 10 such as waste paper products is shown. Thesystem 10 receives waste paper feed 15 which can be old newsprint,telephone books, magazines, paper sludge, or any other suitable paperproduct. Alternatively, other materials such as peanut hulls, green ordry wood shavings, rice hulls, straw, or any other readily availablevegetative material can be used as a base material for the processdescribed herein. The cellulosic material is preferably less than twentypercent moisture. Waste paper feed 15 is received by a charge conveyor20 from a wheel loader, (not shown), or any other means for loading theconveyor.

[0043] A driven conveyor belt moves the waste paper feed 15 along thecharge conveyor 20, which discharges to an inclined conveyor 30.

[0044] An inclined conveyor 30 receives the waste paper feed 15 fromcharge conveyor 20, and 20 includes a driven conveyor belt which movesthe waste paper feed 15 along the inclined conveyor 30. A metal detector40 can be provided over the driven conveyor belt to assist in metalremoval from the waste paper feed 15. A metal detector 40 can beinterlocked with the driving means for the driven conveyor belt toautomatically stop the conveyor and sound an alarm when metal isdetected, so that the metal can be manually removed.

[0045] Alternatively, an automatic metal removal system incorporatingmagnets or other metal removal means can be provided. An inclinedconveyor 30 discharges the paper feed with the metal removed 45 to aprimary grinder 50, or pre-shredder 50. The primary grinder 50preferably is a tub grinder comprising grinding elements directlycoupled to an electric rotor drive and, in preferred form, is capable ofreducing hardcover textbooks with no pre-grinding required. An airstream through the primary grinder 50, generated by the primary transferblower 60 described below, is preferably provided to clear paper fromthe rotor. An example of a suitable primary grinder is the DuraTechIndustries International, Inc. Model No. EC-900. Primary grinder 50reduces the size of the paper feed 45 into approximately two inch (2″)paper chips. As the paper chips exit the primary grinder 50 they areentrained in paper chip discharge flow 55. It will be understood bythose of ordinary skill in the art that a hammermill may be used inplace of the described tub grinder.

[0046] The paper chip discharge flow 55 is pulled from the primarygrinder 50 by a primary transfer blower 60. The discharge from theprimary transfer blower 60 enters a cyclone separator 70, whichseparates the paper chips 74 from the air stream 76. Air stream 76 isdirected to a dust collector 78 which removes dust from the air streamby means of air permeable bags, filters, or other dust separation means.The dust collector 78 also preferably includes means for shaking dustfrom the collection bags or filters, and means for removing andcollecting the accumulated dust. Clean air is exhausted from the dustcollector 78 to the atmosphere. DuraTech Model No. 6108 has been foundto provide satisfactory performance as a dust collector. In someinstances, it may be desirable to reintroduce the dust collected by dustcollector 78 into the process stream. This can be achieved by providingan auger-driven discharge from the dust collector 78 to the point in thesystem where reintroduction of the dust is desired.

[0047] Paper chips 74, separated by the cyclone separator 70, aredischarged to a fiberizer surge tank 80 which provides an airlock toassist the cyclone in separating the paper chips 74 from the dischargeflow 55. The fiberizer surge tank 80 also provides an airtight seal toprevent the escape of paper fiber dust to the work area. By holding aquantity of paper chips 74, surge tank 80 ensures a continuous supply ofchips to the fiberizer, described below. The fiberizer surge tank 80 ispreferably provided with agitating or vibration-inducing means toprevent the paper chips 74 from bridging the outlet, and to ensure asmooth flow from fiberizer surge tank 80 to the fiberizer 90.Transparent windows can be provided in the walls of the fiberizer surgetank 80 to permit visual confirmation of grinder performance, and toprovide visual confirmation of paper chip flow. DuraTech Model No. 7280has been found to provide suitable performance as fiberizer surge tank80.

[0048] Feeder screws, gravity, or other transfer means transfer thepaper chips 74 from fiberizer surge tank 80 to a fiberizer 90. Fiberizer90 is a size reduction process machine which receives paper chips fromthe surge tank 80 and grinds or “smears” the relatively large paperchips 74 between two large discs having a plurality of ridges thereon.This process transforms the chips into very small paper fibers 108. Forpest control insulation material, it has been found that sizes of 2-26mm result in the best quality product.

[0049] DuraTech Model No. LDF-2 has been found to provide suitableperformance as a fiberizer 90.

[0050] After fiberizing the cellulosic chips, it may be preferable toadd further cellulosic material to the fibers for some applications. Asstated above, the dust collected after grinding the material may bereintroduced. Furthermore, materials such as unground rice hulls may beadded for bulk.

[0051] One or more dry chemical additives 106 can be introduced to thepaper fibers 108. The dry chemical additives 106 are preferablyintroduced just before the fiberizer, which agitates the mixture ofpaper fibers 108 and dry chemical additives 106 during the grinding toprovide more thorough and even distribution of the dry chemicaladditives 106. Dry chemical additives 106 are often obtained in bulksolid or pellet form, and are loaded in chemical mixing hopper 100 foruse. A chemical feeder 102 supplies dry chemical additives to apulverizer 104 which pulverizes the dry chemical additive 106 prior tointroduction into the paper fibers 108.

[0052] Paper fibers 108, which are discharged from the fiberizer 90, arepreferably transferred to a moiler 120 via a moiler feed line 114. Thefibers are pneumatically transported through the moiler by means of ablower or fan, such as the secondary transfer blower 150. A divertervalve 110 can be provided at the discharge of fiberizer 90 to transferthe paper fibers 108 via moiler bypass 116 for immediate packaging inthe event the use of the moiler is unnecessary in a given application.

[0053] As shown in greater detail by FIG. 2, the moiler 120 is anapparatus which allows introduction of liquid additives 124 into thepaper fibers 108 comprising moiler feed 114. The introduction of liquidadditives, as opposed to (or in addition to) dry additives, has beenfound advantageous, as it allows a more even and thorough distributionof the additive to the paper fibers. Liquid additives readily adhere tothe fibers, and also promote greater adherence of dry additives to thefibers. This can help dramatically cut dust down, during wall and atticapplications of insulation.

[0054] Due to the fact that the fiberized paper is very light andaerodynamic, while commonly used dry additives are relatively heavy andless aerodynamic, dry additives introduced according to known methodsoften do not properly attach to the paper fibers and will drop out ofthe product as the product is processed and pneumatically conveyed. Thisoften results in uneven application of the dry additives to the finalproduct.

[0055] To overcome this problem, previous manufacturing methods havesimply increased the volume of the dry additives to ensure that aminimum amount of additives is provided throughout the final product.Increasing the volume of dry additives, however, results incorresponding increases in production costs. By introducing additives inliquid form, it has been found that a consistent blend of paper fibersand additive, and better adherence between the additive and the fibersare provided. This liquid additive can also greatly reduce dust duringbuilding application procedures. By providing a consistent, even mix ofadditive and paper fibers, the overall usage of additives may beminimized, increasing system efficiency without sacrificing productquality. The specific additives which are applied to the paper fiberscan vary, depending upon the desired characteristics and application ofthe final product.

[0056] The moiler 120 includes one or more atomizers 122 which mix aliquid additive 124 with pressurized air, supplied from an not showncompressor or air pump, and inject the air/liquid additive mixture ontothe paper fibers 108. Liquid holding tank(s) or reservoir(s) can beprovided for maintaining a working quantity of the liquid additive(s)124. The liquid additive 124 can be pumped from the liquid holdingtank(s), or can be gravity fed. It is preferable that the liquidadditive(s) 124 and the pressurized air be supplied at constantpressures and flow rates to ensure a consistent and even mix of liquidadditive(s) 124 with paper fibers 108.

[0057] The moiler 120 preferably comprises ductwork of varyingdiameters, thereby creating eddies in the air flow through the moiler120. These eddies impart a mixing, tumbling action on the paper fibers108 in the moiler 120 to enhance the liquid/solid mixture, as well asallowing the dry and liquid additives time to adhere onto the surfacesof the paper fibers 108 traveling through the duct work. The moilervolume and dimensions will vary depending upon a number of factors,including: the throughput of the system, the quantity of additivesintroduced, and the drying time of the liquid additives.

[0058] The moiler 120 may include removable conduit which facilitateseasy cleanout and enables observation of moiler activity. Although thefigures show the moiler 120 as a separate component, it will beunderstood by those of ordinary skill in the art that moiler 120 can becombined with fiberizer 90, or at any point downstream from thefiberizer 90 in the paper flow. The atomized injection of liquidadditive 124 onto the paper fibers 108, which is enabled by the moiler120 has been found in practice to permit an additive/paper mix of up totwenty percent (20%) additive by weight. Thus, a much higher additivecontent is enabled, as compared to the use of dry chemical additivesalone. It will be understood that the present invention contemplates anadditive/paper mix of over twenty percent (20%), for example, as greatas 90%, additive by weight utilizing other forms of additiveapplication.

[0059] Moiler discharge 126, comprising paper fibers 108 and liquidadditive 124 may alternatively be routed either to a bulk dischargesystem 140 or a baler feed system 145, by diverter valve 130. If it isdesired to package the material in bales, baler (cuber) feed 148 istransferred via secondary transfer blower 150, as shown in FIG. 1, to acyclone separator 152, which separates treated fibers 154 from the airstream 156. The air stream 156 is then processed by a dust collector 158to remove dust prior to exhausting air into the atmosphere. Treatedfibers 154 are collected in a baler surge tank 160, from which thetreated fibers 154 are transferred to a baler tube 170 by means of screwfeeders or other transfer means. A hydraulic ram (not shown) compressesthe treated fibers 154 into a bale and pushes the compressed bale into aplastic bag or other packaging material.

[0060] If it is desired to collect the final product in bulk form,diverter valve 130 will be actuated to transfer to bulk discharge system140. A transfer blower, cyclone separator, and dust collector similar tothat described above can be provided to permit separation of the treatedfibers from the air flow.

[0061] A bulk airlock feeder 180, shown in preferred form by FIG. 3, canbe provided to receive the treated fibers 182 from the discharge of thebulk discharge system's cyclone separator. The bulk airlock feeder 180receives the fibers 182 in its standpipe 184, by gravity feed. Thestandpipe 184 can be provided with a sight glass 186 for visualconfirmation of material flow and condition. One or more level sensors188 can also be provided for remote monitoring and control, and to shutthe system down in the event of a blockage.

[0062] The treated fibers 182 discharge from the standpipe 184 into agenerally horizontal discharge tube 190. Discharge tube 190 houses anauger (not shown) which is rotationally driven, as by a motor 192 and agearbox 194. A chain or belt drive, or other transmission means (notshown), transmits power from the motor 192 to the gearbox 194 and auger(not shown). A belt or chain guard 196 is preferably provided.

[0063] As the not shown auger rotates, it propels the fibers 182 throughthe discharge tube 190, in the direction of discharge hatch 198.Discharge hatch 198 is connected to discharge tube 190 by hinge means200. By attaching the discharge hatch 198 in the manner shown by FIG. 3,the weight of the hatch 198 acts to maintain the hatch 198 in its closedposition. As the auger presses the fibers 182 against the closeddischarge hatch 198, air is squeezed from the fibers to compress theproduct somewhat for easier handling.

[0064] When a sufficient quantity of compressed fibers 182 haveaccumulated against the discharge hatch 198, the action of the augeragainst the fibers 182 will force the discharge hatch 198 at leastpartially open, thereby permitting compressed fibers 182 to dischargefrom the bulk airlock feeder to a bulk collection station below.

[0065] The height of the standpipe 184 and the length of the dischargetube 190 are selected to allow the creation of an “airlock” within thebulk airlock feeder 180. The airlock is achieved when the standpipe 184and the discharge tube 190 are filled with fibers 182, to a level thatprevents air from the discharge of the cyclone separator from passingthrough the bulk airlock feeder. This minimizes the creation of dust dueto pressurized air blowing through the product. DuraTech Model No. AF-1has been found to provide acceptable results when used as the bulkairlock feeder 180.

[0066] The pest control insulation produced by the method and systemdescribed above has been found to be particularly well-adapted for usein the building industry. The fiberized nature of the insulationproduced by the method and system of the present invention makes theinsulation more fluffy than simple shredded paper. This fluffyinsulation is more absorbent, offers better thermal insulatingproperties, decomposes faster, covers more area per pound of insulationand is easier to handle than simple shredded paper. The increasedsurface area created by fiberizing the base material also allows betteradherence between the base material and additives.

[0067] The introduction of liquid additives to the material through theuse of a moiler, as described above, enables a more even and consistentmix of additives and base material, and improves the adhesion betweenthe base material and the additives. Additives including: antiseptics,fire retardants, pesticides, disease immune additives (medicines),ammonia inhibitors, borates, colorants and fragrance may be provided tothe pest control insulation.

[0068] Regarding animal bedding, ammonia inhibitors such as InhibodorTMand Ammonia HoldTM have been found effective as additives forcontrolling fumes and odors. Ammonia fumes have been found to lead tohigher mortality, poor feed conversion, respiratory tract damage,decreased weight gains, airsacculitis, eye damage and increased diseaseseverity in chickens. The normal manner of controlling ammonia fumes isthrough ventilation. Ventilation fans, however, consume electricity and,during cold weather, exhaust needed heat from the facility. Thus, theaddition of ammonia inhibitors to the bedding, and the resultingreduction in needed ventilation, can significantly improve theprofitability of poultry production operations.

[0069] Pesticides such as orthoboric acid, boron-10 (produced byIncideTM), other borates, SafecideTM, and others have been foundeffective as additives for controlling pests commonly found in poultryproduction facilities. Fungicides, antiseptics, antibacterials, and avariety of other medicinal agents may be included as additives.

[0070] Disease immune additives such as Happy ChickTM may also beincluded within the scope of the present invention. Because the presentinvention enables an even and consistent application of the selectedadditive or additives, and improved adherence of the additive to thebase material, the production of a variety of “prescription” beddingproducts, each having specified desired characteristics, is madepossible.

[0071] The fiberized insulation produced by the method and system of thepresent invention has also been found to have greater water absorbency(by weight of absorbent medium), than hammermilled paper, shreddedpaper, wood chips, sawdust, or cat litter. This results in less frequentbedding replacement, further improving production efficiency.

[0072] While the invention has been disclosed in its preferred forms, itwill be apparent to those skilled in the art that many modifications,additions and deletions can be made therein without departing from thespirit and scope of the invention and its equivalents.

What is claimed is:
 1. Pest control insulation material comprising: a. cellulosic fibers formed of cellulosic waste; and b. a pesticide additive applied to the fibers in liquid form.
 2. The pest control insulation material of claim 1 having a sufficient amount of pesticide additive to qualify as an EPA registered pest control product.
 3. The pest control insulation material of claim 1, the pesticide additive comprising boric acid.
 4. The pest control insulation material of claim 1 further comprising a stabilizer additive for stability and dust control.
 5. The pest control insulation material of claim 4, wherein the stabilizer additive is a starch adhesive.
 6. The pest control insulation material of claim 1 comprising another additive selected from the group consisting of antiseptics, fire retardants, disease immune additives, ammonia dust inhibitors, colorants, stabilizers and fragrances.
 7. The pest control insulation material of claim 1, wherein the cellulosic fibers are selected from the group consisting of fiberized paper, fiberized paper sludge, fiberized peanut hulls, fiberized wood shavings, fiberized rice hulls, and fiberized straw.
 8. The pest control insulation material of claim 1 comprising approximately 15%-20% by weight pesticide additive.
 9. The pest control insulation material of claim 1 comprising greater than 20% by weight pesticide additive.
 10. A method for producing pest control insulation material from cellulosic waste, the method comprising the steps of: a. grinding the cellulosic waste to form cellulosic chips; b. fiberizing the cellulosic chips to form cellulosic fibers; and c. introducing at least one liquid additive to said cellulosic fibers to form the pest control insulation material.
 11. The method according to claim 10, the pest control insulation material having a sufficient amount of liquid additive to qualify as an EPA registered pest control product.
 12. The method according to claim 10, further comprising the step of adding at least one dry chemical additive to said cellulosic fibers.
 13. The method according to claim 10, wherein the liquid additive is introduced to the cellulosic fibers by an atomizer.
 14. The method according to claim 10, wherein the cellulosic fibers are mixed and tumbled while introducing the liquid additive to the cellulosic fibers.
 15. The method according to claim 10, wherein the combination of fibers and pesticide additive comprise approximately 15%-20% by weight pesticide additive.
 16. The method according to claim 10, wherein the combination of fibers and pesticide additive comprise greater than 20% by weight pesticide additive.
 17. A method for producing pest control insulation material from cellulosic waste, the method comprising the following sequential steps of: a. grinding the cellulosic waste to form cellulosic chips; b. fiberizing the cellulosic chips to form cellulosic fibers; and then c. introducing at least one liquid additive to said cellulosic fibers to form the pest control insulation material.
 18. The method according to claim 17, wherein a moiler introduces the liquid additive.
 19. The method according to claim 18, wherein the moiler comprises an atomizer.
 20. The method according to claim 19, wherein the atomizer introduces the liquid additive at a substantially constant rate. 